U.S. patent application number 15/310551 was filed with the patent office on 2017-03-23 for production of two-layer composite deck tile by injection molding method.
This patent application is currently assigned to Sema Plastik Kalip Ve Makine Sanayi Ve Ticaret Ltd.Sti.. The applicant listed for this patent is Sema Plastik Kalip Ve Makine Sanayi Ve Ticaret Ltd. Sti.. Invention is credited to Semih GU BILMEZ.
Application Number | 20170081862 15/310551 |
Document ID | / |
Family ID | 52814175 |
Filed Date | 2017-03-23 |
United States Patent
Application |
20170081862 |
Kind Code |
A1 |
GU BILMEZ; Semih |
March 23, 2017 |
PRODUCTION OF TWO-LAYER COMPOSITE DECK TILE BY INJECTION MOLDING
METHOD
Abstract
The present invention is related to the production method of the
two-layer composite deck tile (1) which comprises the process steps
of melting, first of all, the wood-plastic filling material which
is used as the top layer (10) and filling the same into the
prepared injection mold cavity; then melting the thermoplastic
bottom layer (11) which allows the composite deck tile (1) to be
high-positioned on the ground where it will be applied and filling
the same into the injection mold cavity; allowing the two layers
(10, 11) to cool down which are filled into the mold cavity; and
removing thereof from the mold after cooling down, so as to be used
in the outdoor areas or for floor coverings.
Inventors: |
GU BILMEZ; Semih; (Istanbul,
TR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sema Plastik Kalip Ve Makine Sanayi Ve Ticaret Ltd. Sti. |
Istanbul |
|
TR |
|
|
Assignee: |
Sema Plastik Kalip Ve Makine Sanayi
Ve Ticaret Ltd.Sti.
Istanbul
TR
|
Family ID: |
52814175 |
Appl. No.: |
15/310551 |
Filed: |
February 18, 2015 |
PCT Filed: |
February 18, 2015 |
PCT NO: |
PCT/TR2015/000081 |
371 Date: |
November 11, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 45/16 20130101;
E04F 2201/021 20130101; E04F 15/107 20130101; E04F 15/02038
20130101; E04F 15/02188 20130101; B29C 45/0013 20130101; B32B 3/12
20130101; B29K 2511/14 20130101; B29C 45/40 20130101; B32B 27/20
20130101; E04F 15/02183 20130101; B32B 2419/04 20130101; B29K
2101/12 20130101; E04F 15/102 20130101; B29L 2031/104 20130101;
E04F 2201/0138 20130101; E01C 5/20 20130101 |
International
Class: |
E04F 15/10 20060101
E04F015/10; B29C 45/16 20060101 B29C045/16; E01C 5/20 20060101
E01C005/20; B32B 27/20 20060101 B32B027/20; B32B 3/12 20060101
B32B003/12; E04F 15/02 20060101 E04F015/02; B29C 45/00 20060101
B29C045/00; B29C 45/40 20060101 B29C045/40 |
Foreign Application Data
Date |
Code |
Application Number |
May 14, 2014 |
TR |
2014/05413 |
Claims
1. A production method for two-layer composite deck tiles (1) made
of wood-plastic mixture composite material so as to be used in the
outdoor and indoor areas or for floor coverings, characterized in
comprising the following process steps; melting, first of all, the
wood-plastic filling material which is used as the top layer (10)
and filling the same into the prepared injection mold cavity, then
melting the thermoplastic bottom layer (11) which allows the
composite deck tile (1) to be high-positioned on the ground where
it will be applied and filling the same into the injection mold
cavity, allowing the two layers (10, 11) to cool down which are
filled into the mold cavity, removing thereof from the mold after
cooling down.
2. A two-layer composite deck tile (1) which is obtained with the
method described in claim 1.
3. The composite deck tile (1) according to claim 2, characterized
in that said wood-plastic top layer filling material (10) contains
tree powder, plastic, binders, and additive chemicals.
4. The composite deck tile (1) according to claim 2, characterized
in that said thermoplastic bottom layer (11) is made of a polymer
material such as PE, PP, ABS, EPDM, and PA.
5. The composite deck tile (1) according to claim 2, characterized
in that said thermoplastic bottom layer (11) has geometrical forms
such as cubical, hemispherical, and prism forms which are formed at
regular and/or irregular intervals.
Description
TECHNICAL FIELD
[0001] The present invention relates to the wood-plastic composite
materials used in the outdoor areas such as garden paths,
footbridges, children's playground, balconies, walking paths,
winter gardens, poolside, marinas, docks, beaches, pergolas,
porches, camellias and terraces, boats and yachts, sun terraces,
and areas having a risk of slippery ground and in the indoor areas
such as saunas, hotels, restaurants, cafes, and houses.
STATE OF THE ART
[0002] The deck tile refers to the floor covering in wet grounds
which is produced utilizing wood-plastic mixture composite
materials used in flooring today. Said wood-plastic composites
cannot be used in the plastic injection machines because of the
yield strength and physical endurance thereof and can only be used
in specifically-produced plastic extruder machines. The
wood-plastic composite used in the extruder can only be used for
the production of the products having a flat form such as a profile
and cannot be used for the production of the products having
indent-protrusion details such as trays, plates, toy pieces, and
clothes hangers.
[0003] The composite materials can only be produced by the
extrusion method in the state of the art. A deck tile is produced
by sizing the flat profiles obtained with said method and combining
the same by means of various connection members. However, said
method brings along some disadvantages.
[0004] One of these disadvantages is the raw material losses which
occur while sizing the flat profiles and combining the same by
means of various connection members.
[0005] Another one of these disadvantages is the time loss and
labor costs arisen while sizing the profiles to be combined and
mounting the same.
[0006] One of these disadvantages is that the product produced by
the extrusion method has a low production capacity and increased
energy expenses.
[0007] A further disadvantage is that the material quality depends
on the quality of the production methods due to the restricted
nature of the production method. Therefore, a standardized quality
cannot be achieved.
[0008] A similar disadvantage suggests that the product produced by
the extrusion method does not have an aesthetic look.
[0009] Some applications are encountered during the literature
search.
[0010] One of them is the utility model application numbered
TR200707593 and titled `Composite wood-reinforced plastic panel`.
The invention is related to the composite wood-reinforced plastic
panel used in the construction sector. Said panel is used for
obtaining molds for the concrete structures which constitutes the
carrier element of the building in the reinforced concrete building
construction. It can be used for many times owing to the composite
structure thereof having various layers and provides convenience
during the application.
[0011] In conclusion, due to the drawbacks discussed above and the
inadequacy of the existing solutions with respect to the subject, a
development is deemed necessary in the technical field regarding
the production of the deck tiles.
OBJECTS OF THE INVENTION
[0012] The present invention relates to the production of two-layer
composite deck tile by injection molding method meeting the
abovementioned requirements, eliminating the disadvantages of the
prior art, and introducing some additional advantages.
[0013] The object of the invention is to allow the production of
two-layer wood-plastic composite materials with the injection
method.
[0014] An object of the invention is to provide the deck tiles
produced by this method with certain characteristics which are
recycling, cost-efficiency, long-term endurance, enhanced capacity,
aesthetic look, moisture resistance, fire resistance, oxidation
resistance, water resistance, and high dimensional stability.
[0015] Another object of the invention is to obtain a final product
in a single process without any need for re-sizing the flat
profiles and combining the same as in the prior art.
[0016] A similar object of the invention is to offer resistance to
the fungi and insects, suitability for all kinds of atmospheric
conditions, impact resistance, resistance to slide, easy mounting,
saving on labor, decorativeness, and minimum maintenance.
[0017] Another object of the invention is to contribute to the
recycling by utilizing the waste materials for the production of
the deck tile materials.
[0018] Another object of the invention is to be healthy and
antibacterial, to be painted and polished any time, and not to be
mossed.
[0019] In order to achieve the preceding objects, the present
invention is a production method for two-layer composite deck tiles
made of wood-plastic mixture composite material so as to be used in
the outdoor and indoor areas or for floor coverings, characterized
in comprising the following process steps; [0020] melting, first of
all, the wood-plastic filling material which is used as the top
layer and filling the same into the prepared injection mold cavity,
[0021] then melting the thermoplastic bottom layer which allows the
composite deck tile to be high-positioned on the ground where it
will be applied and filling the same into the injection mold
cavity, [0022] allowing the two layers to cool down which are
filled into the mold cavity, [0023] removing the same from the mold
after cooling down.
[0024] The structural and characteristic features and all the
advantages of the invention will be clearly understood thanks to
the figures given below and the detailed description composed with
reference to these figures. Therefore, the evaluation needs to be
done by taking into consideration these figures and the detailed
description.
FIGURES FACILITATING THE UNDERSTANDING OF THE INVENTION
[0025] The present invention needs to be assessed together with the
figures described below in order to make the best understanding of
the embodiment and the advantages thereof together with the
additional elements.
[0026] FIG. 1A illustrates the bottom perspective view of the
two-layer composite material produced by the injection method
according to the invention.
[0027] FIG. 1B illustrates the bottom perspective view of the
two-layer composite material produced by the injection method
according to the invention and comprising an alternative
embodiment.
[0028] FIG. 2 illustrates the two-dimensional side view of the
two-layer composite material produced by the injection method
according to the invention.
[0029] The drawings do not have to be scaled necessarily and the
details not required for understanding the present invention may
have been ignored. Besides, the elements which are at least
substantially identical or have at least substantially identical
function are shown with the same numerals.
DESCRIPTION OF THE PART REFERENCES
[0030] 1. Two-layer composite deck the
[0031] 10. Wood-plastic top layer
[0032] 11. Thermoplastic bottom layer
[0033] The drawings do not have to be scaled necessarily and the
details not required for understanding the present invention may
have been ignored. Besides, the elements which are at least
substantially identical or have at least substantially identical
function are shown with the same numerals.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In this detailed description, the preferred embodiments of
the two-layer composite deck tile (1) according to the invention
are described only for a better understanding of the subject.
[0035] The composite deck tile (1) according to the invention is a
composite structure containing wood and plastic mixture in order to
be used in the outdoor and indoor areas or for the floor coverings
and comprises two layers (10, 11). These layers are the top layer
(10) which is used as a filling material and the thermoplastic
bottom layer (11) via which the product (1) is fitted on the ground
where it will be applied, which protects the product, provides high
position for the same, and ensures that said product is not damaged
on the ground on which it will be fitted.
[0036] FIGS. 1A and 1B illustrates the bottom perspective view of
the two-layer composite deck tile (1) produced by the injection
method according to the invention.
[0037] The wood-plastic filling material constitutes the top layer
(10) of the two-layer composite deck tile (1) according to the
invention. Said filling material is obtained with the mixture of
the wood and plastic substances. One of the most important raw
materials to obtain this piece is the tree powder. The tree powder
is used as the filling material for the product (1) according to
the invention.
[0038] It is essential to know the structure of the tree and the
role thereof in the composite which it will constitute together
with the polymer so as to obtain a good product. As a result of the
searches carried to this end, it is decided to prefer the tree
powder as the material to be used as the composite mixture.
[0039] The preferred tree powders are combined with the polymer via
binders and it is ensured that the tree powder and the plastic are
adhered. Furthermore, in the preferred embodiment of the invention,
certain chemical additives may be added in order for the product to
contain the characteristics which are desired to be brought to the
composite material (1). The product is provided with
characteristics which enhance the physical properties of the
product such as strength resistance, UV resistance, impact
resistance, high resistance to atmospheric conditions and the like.
The formulation for the content of the additives used is quite
important. It is necessary to be cautious about which chemical
substance will be incorporated at what rate. The desired product is
obtained with the right formulation by carrying out laboratory
studies to this end.
[0040] The bottom layer (11) of the product (1) according to the
invention is on the other hand produced by the injection method
using thermoplastic raw materials (a polymer such as PE, PP, ABS,
EPDM, and PA). Said bottom layer (11) cuts off the connection
between the composite deck tile (1) and the ground and provides an
easy-mounting environment. Besides, it prevents the composite deck
tile (1) from being damaged on the ground on which the product will
be fitted and provides high position for said product.
[0041] In the preferred applications of the invention, said
thermoplastic bottom layer (11) can have a geometrical form such as
cubical, hemispherical, and prism form which is formed at regular
or irregular intervals as seen in FIGS. 1A and 1B.
Production Method
[0042] The two-layer composite deck tile (1) is formed by melting
said top (10) and bottom (11) layers and filling the same into the
molds prepared in a desired form and size depending on the place of
use and then by removing thereof from the mold after cooling down.
This process is named as injection.
[0043] The production method of the two-layer composite deck tile
(1) according to the invention is as follows; [0044] melting, first
of all, the top layer (10) which is a wood-plastic filling material
and filling the same into the prepared injection mold cavity,
[0045] then melting the thermoplastic bottom layer (11) and filling
the same into the mold cavity, [0046] waiting for the two layers
(10, 11) to cool down which are filled into the mold cavity, [0047]
removing thereof from the mold after cooling down and thereby being
ready for use.
* * * * *